Trousers for cyclist and method of making same

ABSTRACT

Trousers for use by cyclists and method of making such trousers, including an insert for protecting cyclist body zones resting against one of a bicycle seat or a saddle, the insert comprising at least one piece of material fastened at its borders to a fabric of the trousers by way e.g. of stitching. The insert includes a base layer made of expandable material, the base layer having a side adapted to be in direct contact with a body of a cyclist. An elastic fabric, elastic in all directions, is fastened onto the side of the base layer, wherein the elastic fabric adapts itself in its dimensions to the movements of a body of a cyclist.

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present application claims priority under 35 U.S.C. §119 ofSwiss application 2001 1106/01, filed on Jun. 18, 2001, the disclosureof which is expressly incorporated by reference herein in its entirety.

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention concerns trousers for cyclists with aninsert protecting the body zones of the cyclist resting against thebicycle saddle, with an insert made from at least a single piece andfastened at its borders to the fabric of the trousers, e.g. bystitching.

[0004] 2. Discussion of Background Information

[0005] Trousers for cyclists of similar type are known in practical useand are marketed worldwide e.g., by the company ASSOS SA at CH-6854 SanPietro di Stabio, Switzerland.

[0006] Also from the patent literature, the use of trousers for cyclistswith a protecting insert is known e.g. from EP-0776615-A2, published onJun. 4, 1997.

[0007] In the case of EP-0776615-A2, which represents the state of theart on which the present invention is based and which is herebyincorporated in its entirety by reference thereto, the protecting insertis made from natural or synthetic leather and presents a very specificshape in order to prevent the seams used for fastening the insert to thefabric of the trousers, from disturbing the cyclist in his action andcausing painful, or at least bothersome abrasion. This type of insertfor trousers for cyclists has proven itself useful with respect to theobjectives for which it was laid out. It has been found however, thatthe relatively stiff material from which the inserts are made, in thesense of limited extensibility, still can cause discomfort to the user,as the insert cannot adapt sufficiently to the movements of the cyclist,especially to the leg movements, and thus tends to provoke undesirablestretching in certain zones of the cyclist's skin. This is due to thefact that the material chosen for the insert, i.e., natural or syntheticleather, presents very low elasticity values, usually below 10% and inmany cases reaching hardly even a few per cent of elasticity. Repeatedstretching of skin zones, which are very susceptible by nature in anyevent, such as the groin zones, can eventually cause local reddening andinflammation of the skin, which are very annoying for the cyclist.

SUMMARY OF THE INVENTION

[0008] The present invention thus intends to eliminate these specificdisadvantages of the trousers for cyclists provided with the knowninserts and to permit realization of clothing for casual cyclists, aswell as and especially for racing competition cyclists by providingoptimum comfort and reliably avoiding any remaining danger of abrasionof delicate body zones particularly exposed while practicing this sport.

[0009] This objective is met using the present invention by having theinsert consist of a base layer made of expanded material, onto which, onthe side directly contacting the body of the cyclist, a fabric, elasticin all directions is fastened in a manner adapting itself in itsdimensions to the body movements of the cyclist.

[0010] Owing to the application of an insert, which is soft as it iscomposed of a base layer made from expanded material, and covered by afabric, elastic in all directions, perfect adaptation of the insert tothe body movements of the cyclist is obtained in such a manner that norelative movement occurs between the skin of the cyclist and the surfaceof the insert, which could cause friction and thus result in abrasion ofthe skin.

[0011] Before beginning the description of various preferred examples ofrealization of the present invention, two general aspects thereof are tobe clarified more precisely, namely:

[0012] The present invention does not concern the actual shape of theinsert to be inserted in the appropriate zone of the seat of thetrousers. The insert thus can present a shape similar to the oneprovided in the above-mentioned EP-0776615-A2, and can also be of anyother shape deemed advantageous.

[0013] The term “fabric elastic in all directions” herein is understood,in a general sense, to designate a two-dimensional textile aggregate offiber threads made from natural or synthetic fibers and/or continuousfilaments intertwined in such a manner that an elasticity of the fabricis ensured, which essentially is homogeneous in all directions, i.e. inany direction it is subject to tensile tension.

[0014] According to an aspect of the invention, trousers for use bycyclists include an insert for protecting cyclist body zones restingagainst one of a bicycle seat or a saddle, the insert comprising onesingle piece of material fastened at its borders to a fabric of thetrousers, e.g., by way of stitching. The insert comprises a base layermade of expandable material, the base layer having a side adapted to bein direct contact with a body of a cyclist. An elastic fabric, elasticin all directions, is fastened onto the side of the base layer, whereinthe elastic fabric adapts itself in its dimensions to the movements of abody of a cyclist.

[0015] According to another aspect of the invention, the base layer maybe made from foam rubber. The elastic fabric may comprise a fabric madewith elastomer fibers with an elastic elongation capacity of more than5%. The base layer may comprise a soft expandable material. The softexpandable material, in its load-free relaxed state, may be of athickness (h) ranging from approximately 1 mm to approximately 8 mm andpreferably from approximately 3 mm to approximately 5 mm.

[0016] According to yet another aspect of the invention, the elasticfabric may be fastened to the base layer of expandable material by usingadhesives, the adhesive remaining elastic in a fixed state afterapplication. The elastic fabric may be fastened to the base layer by wayof stitching, using a stitch bonding process. The elastic fabric may befastened to the base layer by way of a hot vulcanizing process. Theelastic fabric may comprise a woven fabric, using threads withelastomeric fibers in a weft as well as in a warp. The elastic fabricmay comprise a knitted fabric, knitted using a thread with elastomericfibers.

[0017] Moreover, according to the invention, trousers for use bycyclists include an insert for protecting cyclist body zones restingagainst one of a bicycle seat or a saddle, the insert comprising onesingle piece of material fastened at its borders to a fabric of thetrousers by way of stitching. The insert comprises a base layer made ofsoft expandable material, the base layer having a side adapted to be indirect contact with a body of a cyclist. An elastic fabric, elastic inall directions, is fastened onto the side of the base layer, wherein theelastic fabric adapts itself in its dimensions to the movements of abody of a cyclist. The soft expandable material, in its load-freerelaxed state, may be of a thickness (h) ranging from approximately 1 mmto approximately 8 mm.

[0018] According to the invention, the elastic fabric may be fastened tothe base layer of expandable material using adhesives, the adhesiveremaining elastic in a fixed state after application. Alternatively, theelastic fabric may be fastened to the base layer by way of stitching,using a stitch bonding process. Furthermore, the elastic fabric may befastened to the base layer by way of a hot vulcanizing process. Theelastic fabric may comprise a woven fabric, using threads withelastomeric fibers in a weft as well as in a warp. The elastic fabricmay comprise a knitted fabric, knitted using a thread with elastomericfibers.

[0019] According to a further aspect of the invention, a method ofmaking trousers for use by cyclists including at least a piece ofmaterial insert for protecting cyclist body zones resting against one ofa bicycle seat or a saddle, comprises fastening the insert at itsborders to a fabric of the trousers, e.g. by way of stitching, theinsert comprising a base layer made of expandable material, the baselayer having a side adapted to be in direct contact with a body of acyclist and fastening an elastic fabric, elastic in all directions, ontothe side of the base layer, wherein the elastic fabric adapts itself inits dimensions to the movements of a body of a cyclist.

[0020] According to the invention, the fastening of the elastic fabricmay comprise fastening the elastic fabric to the base layer ofexpandable material by using adhesives, the adhesive remaining elasticin a fixed state after application. Alternatively, the fastening of theelastic fabric may comprise fastening the elastic fabric to the baselayer by way of stitching, using a stitch bonding process. Further yet,the fastening of the elastic fabric may comprise fastening the elasticfabric to the base layer by way of a hot vulcanizing process.

[0021] Other exemplary embodiments and advantages of the presentinvention may be ascertained by reviewing the present disclosure and theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0022] The present invention is further described in the detaileddescription which follows, in reference to the noted plurality ofdrawings by way of non-limiting examples of embodiments of the presentinvention, in which like reference numerals represent similar partsthroughout the several views of the drawings, and wherein:

[0023]FIG. 1 shows a schematic perspective view of a cyclist (off hisbicycle) wearing the inventive trousers;

[0024]FIG. 2 shows a detail according to FIG. 1 on an enlarged scale,showing the insert developed into a plane;

[0025]FIG. 3 shows a cross-section along the line A-A according to FIG.2, of a variant realization of the present invention; and

[0026]FIG. 4 shows a variant, in the same view as the one shown in theFIG. 3, of another form of realization of the present invention.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0027] The particulars shown herein are by way of example and forpurposes of illustrative discussion of the embodiments of the presentinvention only and are presented in the cause of providing what isbelieved to be the most useful and readily understood description of theprinciples and conceptual aspects of the present invention. In thisregard, no attempt is made to show structural details of the presentinvention in more detail than is necessary for the fundamentalunderstanding of the present invention, the description taken with thedrawings making apparent to those skilled in the art how the severalforms of the present invention may be embodied in practice.

[0028]FIG. 1 illustrates a portion of trousers for cyclists, designated1, and more precisely the portion corresponding to the groin zone, theperson wearing the trousers standing on the ground. An insert,designated 2, made from a single piece is fixed at its borders 3 (bettervisible in FIG. 2) to the fabric of the trousers 1 for cyclists by astitching seam. The seam 4 is indicated in FIG. 2 by a zigzag line.

[0029] The shape of the insert, which as such is not an object of thepresent invention, can be e.g. pear-shaped, as indicated in FIG. 2,where the larger portion of the pear outline coincides, after being puton by the cyclist, with the anterior zone of the body, i.e. the zone ofthe sexual organs, which are particularly susceptible to mechanicalstress, and thus merit effective protection. As underlined above, thepear shape of the insert 2 is not, however, necessary within the scopeof the present invention, which can advantageously be applied also toinserts of other shapes, depending on the requirements and keeping thegender of the user in mind.

[0030] For a better understanding of the present invention, FIG. 3 willnow be referred to, in which a cross-section along the line A-Aaccording to FIG. 2 is shown. From FIG. 3 it can be seen how the insert2 is composed of a base layer 5 of expanded soft material onto which, onthe side directly contacting the body of the cyclist, a fabric 6,elastic in all directions, according to the definition given aboveconcerning the concept of elasticity, is fastened or attached. Owing tothe isotropic or homogeneous elasticity of the material covering theinsert, the latter can adapt its dimensions to the movements of the bodyof the cyclist, and thus permits realization of the objective statedabove for the present invention.

[0031] According to a first variant of realization of the presentinvention, the base layer 5 of expanded material consists of foamrubber: the advantage of this solution being mainly the price of thismaterial, as the so-called foam rubber is a low-price material availablepractically everywhere.

[0032] According to a further variant of realization of the presentinvention, the fabric 6, elastic in all directions, is a fabricincorporating elastomer fibers, such as a fiber called Elasthan,marketed under the Lycra trademark of the Du Pont de Nemurs Corp.

[0033] It is important however, within the scope of the presentinvention, that the elastomer fiber present a capacity of elongation ofmore than 5%. This indication intends to exclude from the field ofapplication of the present invention all fibrous materials the elasticelongation of which is lower than 5% of their length in the absence oftensile tension. It is clear that every material has its specificcoefficient of elasticity (called elasticity modulus), but within theframe of the present invention preferentially materials are to bechosen, which present a certain elasticity, as indicated in thisspecific preferred form of realization of the present invention.

[0034] According to another preferred form of realization of the presentinvention, aimed at ensuring maximum comfort to the user of thetrousers, the base layer 5 of expanded material present, in its statefree of load, i.e. not subject to any compressing effect, is to be of athickness h (compare the FIG. 3) ranging from approximately 3 mm toapproximately 5 mm. Experience has shown that these dimensions representthe limits of the thickness h ensuring optimum wearing comfort of thetrousers while meeting the objectives of the present invention, and atthe same time ensuring the required stability of the cyclist in thesaddle. It is known (compare also the statements in this respect in theabove-mentioned EP-0776615-A2) that good stability of the cyclist seatedon the saddle represents a most important security aspect for thecyclist, and such stability—also called anchoring—requires that thesupport of the cyclist on the saddle not be excessively soft. Thus,there are limits to the softness of the insert, which should not beexceeded.

[0035] There are several possibilities of fastening or attaching thefabric 6 to the base layer 5 of expanded material, each of whichpresents its specific advantages and can constitute, according to thespecific production facilities, the number of items to be produced, thematerials applied, etc., particularly convenient solutions.

[0036] Thus, for relatively modest production runs it might proveeconomically feasible to realize fixation or attachment between thefabric 6 and the layer 5 of expanded material by way of adhesivefixation using an elastic adhesive, which in its fixed state afterapplication, remains elastic, such as e.g. a contact adhesive. This typeof fixation can also be performed in a craftsman-type workshop and thusis feasible for small production runs for limited series of trousers forcyclists.

[0037] Another solution, for larger production runs, is the one shown inFIG. 4, indicating the manner in which the fabric 6 is fastened to thebase layer 5 of expanded material by stitch bonding, applying seams. InFIG. 4 the seam or stitching threads, designated by reference number 7,bind the layer of elastic fabric 6 onto the base layer below. Theproduction of such stitch bonding items is known in practicalapplication and is applied on large surfaces using continuouslyoperating machines, called stitch bonding machines (usually of theArachne or the Mali type) machines, producing endless tapes of widths ofup to several meters at high speed. In such cases the inserts 2 must bestamped from the tape of material using suitably shaped templates. Forensuring the desired elasticity of the inserts obtained, as requiredaccording to the present invention, it may prove advantageous for thestitching thread to contain elastomer fibers.

[0038] According to another preferred form of realization of the presentinvention, feasible for very large production runs and applicable onlyunder certain conditions, concerning the heat properties of thematerials being processed, it provides that the fabric 6 be fastened tothe base layer 5 of expanded material by way of heat vulcanization.Also, this production method permits production of inserts suitable formeeting the objectives of the present invention, being provided with therequired mechanical properties, at much reduced cost and in greatquantities.

[0039] According to a further preferred form of realization of thepresent invention, the fabric 6 is a woven fabric in which the weftthreads as well as the warp threads are produced using elastomer fibers.The advantages of weaving in, producing large flat plane textilesurfaces are well known.

[0040] According to another variant, better suited for manufacturingsmall surfaces of elastic fabric 6 of high elasticity, the fabric 6 isknitted from a thread produced with elastomer fibers. This solution,benefiting of the known properties of knitted fabrics, permits obtainingfabrics of the highest degree of elasticity in all directions and thusis particularly suited for realizing this form of the present invention.

[0041] The present invention has been described here merely in the senseof examples of application in trousers for cyclists, and morespecifically in the zones subject to the danger of abrasion of the skinof the wearer. It is evident that the same solution can be adopted forother applications in connection with the practice of sports other thancycling, where the same abrasion problems of the skin of the athletepersist.

[0042] It is noted that the foregoing examples have been provided merelyfor the purpose of explanation and are in no way to be construed aslimiting of the present invention. While the present invention has beendescribed with reference to an exemplary embodiment, it is understoodthat the words which have been used herein are words of description andillustration, rather than words of limitation. Changes may be made,within the purview of the appended claims, as presently stated and asamended, without departing from the scope and spirit of the presentinvention in its aspects. Although the present invention has beendescribed herein with reference to particular means, materials andembodiments, the present invention is not intended to be limited to theparticulars disclosed herein; rather, the present invention extends toall functionally equivalent structures, methods and uses, such as arewithin the scope of the appended claims.

List of the Elements Referred to in the Figures

[0043] 1  Trousers for cyclists 2  Insert 3  Border of the insert 4 Stitching seam 5  Base layer 6  Elastic fabric 7  Stitching thread

What is claimed:
 1. Trousers for use by cyclists including an insert forprotecting cyclist body zones resting against one of a bicycle seat or asaddle, said insert comprising at least one piece of material fastenedat its borders to a fabric of the trousers by way e.g. of stitching,said insert comprising: a base layer made of expandable material, saidbase layer having a side adapted to be in direct contact with a body ofa cyclist; an elastic fabric, elastic in all directions, fastened ontosaid side of the base layer, wherein said elastic fabric adapts itselfin its dimensions to the movements of a body of a cyclist.
 2. Thetrousers according to claim 1, wherein the base layer is made from foamrubber or other shock absorbing material.
 3. The trousers according toclaim 1, wherein the elastic fabric comprises a fabric made withelastomer fibers with an elastic elongation capacity of more than 5%. 4.The trousers according to claim 1, wherein the base layer comprises asoft expandable material.
 5. The trousers according to claim 4, whereinthe soft expandable material, in its load-free relaxed state, is of athickness (h) ranging from approximately 1 mm to approximately 8 mm. 6.The trousers according to claim 5, wherein the soft expandable material,in its load-free relaxed state, is of a thickness (h) ranging fromapproximately 3 mm to approximately 5 mm.
 7. The trousers according toclaim 1, wherein the elastic fabric is fastened to the base layer ofexpandable material by using adhesives, the adhesive remaining elasticin a fixed state after application.
 8. The trousers according to claim1, wherein the elastic fabric is fastened to the base layer by way ofstitching, using a stitch bonding process.
 9. The trousers according toclaim 1, wherein the elastic fabric is fastened to the base layer by wayof a hot vulcanizing process.
 10. The trousers according to claim 1,wherein the elastic fabric comprises a woven fabric, using threads withelastomeric fibers in a weft as well as in a warp.
 11. The trousersaccording to claim 1, wherein the elastic fabric comprises a knittedfabric, knitted using a thread with elastomeric fibers.
 12. Trousers foruse by cyclists including an insert for protecting cyclist body zonesresting against one of a bicycle seat or a saddle, said insertcomprising at least one piece of material fastened at its borders to afabric of the trousers e.g. by way of stitching, said insert comprising:a base layer made of soft expandable material, said base layer having aside adapted to be in direct contact with a body of a cyclist; anelastic fabric, elastic in all directions, fastened onto said side ofthe base layer, wherein said elastic fabric adapts itself in itsdimensions to the movements of a body of a cyclist, wherein the softexpandable material, in its load-free relaxed state, is of a thickness(h) ranging from approximately 1 mm to approximately 8 mm.
 13. Thetrousers according to claim 12, wherein the elastic fabric is fastenedto the base layer of expandable material using adhesives, the adhesiveremaining elastic in a fixed state after application.
 14. The trousersaccording to claim 12, wherein the elastic fabric is fastened to thebase layer by way of stitching, using a stitch bonding process.
 15. Thetrousers according to claim 12, wherein the elastic fabric is fastenedto the base layer by way of a hot vulcanizing process.
 16. The trousersaccording to claim 12, wherein the elastic fabric comprises a wovenfabric, using threads with elastomeric fibers in a weft as well as in awarp.
 17. The trousers according to claim 12, wherein the elastic fabriccomprises a knitted fabric, knitted using a thread with elastomericfibers.
 18. A method of making trousers for use by cyclists including atleast a piece of material insert for protecting cyclist body zonesresting against one of a bicycle seat or a saddle, said methodcomprising: fastening said insert at its borders to a fabric of thetrousers by way e.g. of stitching, said insert comprising a base layermade of expandable material, said base layer having a side adapted to bein direct contact with a body of a cyclist; and fastening an elasticfabric, elastic in all directions, onto said side of the base layer,wherein said elastic fabric adapts itself in its dimensions to themovements of a body of a cyclist.
 19. The method according to claim 18,wherein the fastening of the elastic fabric comprises fastening theelastic fabric to the base layer of expandable material by usingadhesives, the adhesive remaining elastic in a fixed state afterapplication.
 20. The method according to claim 18, wherein the fasteningof the elastic fabric comprises fastening the elastic fabric to the baselayer by way of stitching, using a stitch bonding process.
 21. Themethod according to claim 18, wherein the fastening of the elasticfabric comprises fastening the elastic fabric to the base layer by wayof a hot vulcanizing process.